Offload

Pump

Soap

Pump

Fluid Waste collected

through Manifold Drain Valve

Waste Coupling

extends from Docker to

mate with Rover

Fluid Waste pumped

to hospital waste

water system

Fluid Waste System Theory of Operation

At the Docking Station, fluid waste is removed from the Rover’s Canisters and discarded into the hospitals waste water

system. This docking process proceeds automatically when the Rover is pushed into the Docking Station. The general fluid

waste transfer steps involved are:

The Docking Station connects to the dry break Waste Coupling on the bottom of the Rover

Waste Fluid is pulled from the Large Canister and discarded by the Docker’s Offload Pump

Waste Fluid from the Small Canister is dumped into the Large Canister by opening the Drain Valve

The Offload Pump continues running until all waste is removed

Canisters are washed and related water is offloaded in the same manner

Drain Valve

The Drain Valve between Canisters is a motor actuated Ball Valve connected to a motor control circuit. Its position (open/

closed) is determined by a hall sensor mounted to the front of the motor.

Small Canister Clogging

During the docking cycle, clotted blood may not drain from the Small Canister to the Large Canister by the force of gravity

alone. To increase the effectiveness of the offload process, the Large Canister is sealed as the Small Canister is drained.

This allows the Offload Pump to draw a vacuum (up to ~ 6 in-Hg) on the Large Canister. This vacuum, in addition to the

force of gravity, pulls clotted blood from the Small Canister through the Drain Valve.

Fluid Waste Handling System

Mechanical

Fluid Waste Subsystem-090622-SREA

Fresh Water System Theory of Operation

At the Docking Station, the Rover Canisters are washed using the normal hospital water supply pressure. Cleaning water is

transferred from the Docking Station to the Rover via dry break couplings. The flow of water within the system is controlled

by a Water Solenoid Valve in the Docking Station. The water’s destination (Small or Large Canister) is controlled by the

Diverter Valve (two solenoid valves) located in the Rover.

Prefill

To enable fluid volume measurement, both Canisters require a small amount of clean water be added after they are

offloaded. This prefill water also includes a small amount of detergent to aid in cleaning during the next docking cycle. At

the Docking Station, prefill water is added through the spray ball in each Canister

The Small Canister can be emptied into the Large Canister away from the Docking Station. This allows the user to fill the

Small Canister multiple times before returning to the Docking Station (i.e. multiple surgical uses between docking cycles). To

prefill the small canister away from the Docking Station, the Rover utilizes water stored in its internal Prefill Tank. Water is

pulled from the Prefill Tank by the Prefill Pump and added to the Small Canister.

Note that the plumbing configuration within the Rover ensures that the Prefill Tank is filled automatically during Docking.

Detergent Dispensing

Detergent is mixed with rinse water inside the Docking Station to improve Canister cleaning. Detergent is dispensed by the

Soap Pump at specific points during the docking cycle to maximize cleaning effectiveness.

Water Temperature and Pressure

Water temperature and the flow rate can significantly affect the ability of the system to clean itself. Since the system does

not control either of these parameters, it is important that the hospital plumbing be set up according the the system’s

installation instructions.

Warm water, up to 110°F, provides the best cleaning. Temperatures above this can ‘cook’ the blood in the system causing

offload problems. High temperatures can also damage internal plumbing components. Low temperatures tend to be less

effective at removing fats.

Solenoid Valve Sequencing

To prevent trapping high pressure water in the Rover and Docker Couplings, the solenoid valves are automatically opened

and closed in a specific sequence.

When turning the water on, the proper Diverter Valve is opened first, followed by the Docker Solenoid.

When turning the water off, the Docker Solenoid is closed first, followed by the Diverter Valve.

When extending or retracting Couplings, the Diverter Valve is opened to prevent pressure in the Couplings from stalling the

Coupling Actuator in the Docking Station.

Offload

Pump

Soap

Pump

Prefill

Pump

Prefill Tank

Fresh water in from

hospital water supply

Detergent drawn from

external bottle

Water Solenoid Valve

Backflow Prevention

Check Valve

Diverter Valve directs water

to either the Small or Large

Canister

Prefill

Tank

Spray Ball in

each Canister

Water Coupling

extends from Docker

to mate with Rover

Fresh Water Handling System

Mechanical

Fresh Water Subsystem-090504-SREA

Level Sensor Theory of Operation

In the Operating Room, the Rover monitors and displays the fluid level of each Canister to the user. Fluid levels are also

used to ensure the docking cycle is carried out correctly. The Level Sensing system is comprised of a Level Sensor Rod,

two magnetic Sensor Floats, and two Reference Magnets attached to the bottom of the Canisters.

To make a volume measurement, an electrical current Interrogation Pulse is sent from the Level Sensor electronics down a

wire inside the Level Sensor Rod. When this current pulse passes by each of the four magnets, a mechanical Return Pulse

is sent back up the Level Sensor Rod. The time between return pulses is used to determine the distance between each

Canister’s Sensor Float and Reference Magnet. This time is used to calculate the fluid volume. See the timing diagram

below for a visual description of this process.

Canister Calibration

Manufacturing variation between Canisters (i.e. canister shape, reference magnet position, etc.) is addressed by factory

calibration of each one produced. A Canister’s calibration information is stored in a permanently attached Canister

Calibration PCBA. This calibration information is read by the Rover’s Main Controller at every power up, preventing the need

for field calibration when canisters are replaced.

Float Calibration

Manufacturing variation between Floats (i.e. float weight, internal magnet placement, etc.) must be addressed by field

calibration. An especially heavy Sensor Float would sit lower in the canister fluid than a light one. This would result in a

different Float-Reference magnet distance for a given fluid volume. The Float Calibration Procedure must be performed any

time a Rover’s floats are changed.

Float calibration information is stored on the Rover Main Controller PCBA. Consequently, the F Float Calibration Procedure

must be repeated when this PCBA is replaced.

Since the time between return pulses is not dependent on which sensor is used, the Float Calibration Procedure does not

need to be repeated when the Level Sensor Rod is replaced.

Canister Temperature

The diameters of the Fluid Collection Canisters increase or decrease with temperature due to thermal expansion. Because

fluid volume calculations take this geometry change into account, the Canister Calibration PCBA’s also include sensors to

measure Canister temperature.

Volume Display

Level Sensor

electronics

Sensor Float

(magnetic)

Reference Magnet

attached to Canister

Canister

Calibration PCBAs

Sensor Float

(magnetic)

Reference Magnet

attached to Canister

Distance between magnets

corresponds to fluid volume

Large Canister

return pulses

V

Time (microseconds)

Interrogation

Pulse Sent

Return Pulse from

Small Canister Float

Return Pulse from Small

Canister Reference Magnet

Time between pulses

corresponds to distance

between Float and

Reference Magnet

Level Sensor System

Mechanical

Level Sensor Subsystem-090527-SREA

Smoke

Evacuator

ULPA

Filter

Smoke

Evacuator

Blower

Smoke collected

through filter inlet

Filtered Air exhausted

inside Rover

Cooling Air Inlet

Smoke Sensor included

in ULPA Filter

Smoke Evacuator Theory of Operation

The Rover’s Smoke Evacuation system is activated by pressing a button on the User Interface Panel. The Smoke Blower

speed can also be selected to offer the right trade-off between noise and smoke evacuation effectiveness.

Air containing smoke is evacuated from the surgical site and filtered before being discharged back to the room. The Smoke

Filter removes smoke particulate using ULPA rated filter media and captures other volatile chemicals with an activated

carbon bed.

Manual Mode

When operated in Manual Mode, the Smoke Evacuator Blower runs at a constant speed regardless of the level of smoke

present in the OR air.

Auto Mode

A Smoke Sensor is built into the ULPA filter for identifying when smoke is actually being generated at the surgical site.

When placed in Auto Mode, the Smoke Evacuator Blower defaults to a low speed to ‘sniff’ for smoke. This ‘sniffing’ speed

was selected to minimize the Blower’s audible noise.

If a smoke plume is generated, it is drawn into the ULPA filter and detected by the Smoke Sensor. The Blower speed is

immediately increased to more effectively evacuate the plume. When smoke is no longer detected, the Blower returns to

‘sniffing’ speed until additional smoke is generated.

Smoke Blower Speed Control

Circuitry controlling the Smoke Blower Motor is designed to ensure its speed is constant over the expected ranges of mains

line frequency and voltage. The Rover determines the line frequency (50/60 Hz) at power up and continuously monitors and

reacts to line voltage changes while running.

Cooling Air

If run with all of the ULPA Filter inlets closed, the Smoke Evacuator Blower requires cooling air to prevent overheating. This

air is provided by a restrictive porous plastic inlet located inside the Rover.

Smoke Evacuation System

Mechanical

Smoke Evacuator Subsystem-090504-SREA

Vacuum Pump

Muffler

Fluid

Suction

HEPA

Vacuum

Regulator

House Suction Ports

with internal Check

Valves

Check Valves

Vacuum Relief Valve

allows cooling air for

Vacuum Pump

Fluid Waste collected

through Manifold

Air removed from Canister

to create vacuum

Overflow Prevention Float

and Mist Collection Foam

Vacuum Regulator Theory of Operation

The on-board vacuum system is activated by a button on the User Interface and vacuum settings are selected for each

canister through dedicated dials. While there is only one Vacuum Pump in the Rover, the actual vacuum level in each

canister is controlled by two separate Regulator Valves. Each Regulator Valve attempts to maintain its canister at the user

selected vacuum setting by:

connecting the Canister to the vacuum source (Vacuum Pump) to increase it’s vacuum level

connecting the Canister to the atmosphere to decrease (vent) it’s vacuum level

sealing the Canister to maintain it’s current level of vacuum

See the diagrams below for a visual explanation of regulator function.

Regulator Valve position is controlled by a DC Motor driven by a Vacuum Control circuit. Valve position is determined by an

optical Encoder mounted to each Motor. Since the Encoder does not provide absolute position information, an initialization

sequence is performed each time the Rover is powered on. This sequence involves driving the Motor in each direction until

a hard-stop is reached.

Vacuum Measurement

The actual vacuum level of each Canister is monitored by PCB mounted Vacuum Sensors. Each Canister is monitored by a

Primary and Secondary Sensor. The readings from Primary and Secondary Sensors are constantly being compared to each

other to ensure accuracy and detect Sensor failure.

House Suction

The user also has the option of providing suction to the Canisters via the hospital’s wall suction. For this mode of use, the

Regulators do not attempt to control the Canisters’ vacuum level. The Rover must be turned on, however, to ensure the

Regulators are in a position that will allow house suction to work (i.e. not vented to atmosphere).

Check Valves in the House Suction Ports eliminate the need for capping these ports when not in use. Additional Check

Valves at the inlet to the HEPA filter prevent air from being drawn backward through the Vacuum Pump when House Suction

is used

Docking

Regulators are also used during docking to vent or seal Canisters. This facilitates offloading waste and prevents building

pressure while spraying rinse water.

Actual Canister Vacuum

above Set Point

To Vacuum

Pump or

House

Suction

Atmosphere

Vent

Fluid

Collection

Canister

Motor Actuated

Regulator Valve

Actual Canister Vacuum

below Set Point

To Vacuum

Pump or

House

Suction

Atmosphere

Vent

Fluid

Collection

Canister

Power Distribution PCBA

Primary

Vacuum

Sensor

Secondary

Vacuum

Sensor

Vacuum

ControllersActual Vacuum

Signal

Regulator Valve

Position Control

Motor Actuated

Regulator Valve

Actual Canister Vacuum

at Set Point

To Vacuum

Pump or

House

Suction

Atmosphere

Vent

Fluid

Collection

Canister

Motor Actuated

Regulator Valve

Vacuum System

Mechanical

Vacuum Subsystem-090504-SREA

Offload

Pump

Soap

Pump

Docker Coupling Actuator Theory of Operation

During docking, fluid connections are bade between the Rover and Docker to transfer fluid waste and fresh water for

cleaning. The Water and Waste Couplings on the Rover are stationary and mounted to the bottom surface. In the Docking

Station, they are mounted to a movable plate. This plate is raised and lowered by a Stepper Motor riding up and down a

stationary lead screw. Diagrams to the left illustrate the components involved, showing them in the fully extended and

retracted positions..

Coupling position is determined using two digital hall sensors. The Extended Hall Sensor is triggered by a metal Sensor

Flag when the couplings are fully extended. The Retracted Hall Sensor is triggered by the Flag when the couplings are fully

retracted.

The entire coupling mechanism is floated on springs to accommodate misalignment between the Rover and Docking Station.

Power Coupler

An inductive Power Coupler transfers power wirelessly from the Docking Station to the Rover during Docking. The Power

Coupler functions much like a transformer with a primary winding located in the Docking Station and a secondary winding in

the Rover. The two transformer halves are brought together when the Rover is pushed into the Docking Station, which

allows for power transfer.

Power Coupler

Water and

Waste Couplings

Lead Screw

Stepper Motor

Couplings shown extended

Sensor FlagExtended Hall Sensor

Retracted Hall Sensor

Couplings shown retracted

Coupling mechanism

shown in detail above

Movable

Coupling Plate

Springs to float

Coupling

Mechanism

Coupling and Actuation System - Docker

Electrical

Coupling Actuation Subsystem-090617-SREA

IV Pole Theory of Operation

The Rover’s IV Pole is raised and lowered in response to buttons pressed on the User Interface Panel. The Pole is driven by

a DC motor and associated control circuitry. The Motor contains an integral Brake, which when powered, holds the Pole at

the desired height. The mechanism connecting the IV Pole Motor to the IV Pole is illustrated in the diagram below.

Auto Down Feature

When power is removed from the Rover, the IV Pole Brake releases automatically. As the pole begins to drop under its own

weight (and the force of an internal Return Spring), the Motor is mechanically back-driven by the falling Pole. In this

instance, the Motor acts as electrical generator and provides power to run a speed control circuit. The speed control circuit

electronically brakes the Motor to limit the speed of the descending Pole.

Since the speed of Pole descent is controlled by the Motor, if it is electrically disconnected from the rest of the system, the

Pole will fall rapidly.

Moving IV Pole

Moving Pole

attached to Belt

Motor drives this Pulley, moving

Belt to raise or lower IV Pole

Integral Brake on Motor holds Pole

at desired height

Idler Pulley at top of

stationary Pole Support

IV Pole Motor with

integral Brake

Moving IV Pole

Stationary (outer) IV Pole

Stationary

Pole Support

IV Pole System

Mechanical

IV Pole Subsystem-090504-SREA

brown

Power

Switch / CB

red

white

black

gray

gray

blue

violet

violet

Power Distribution PCBA

0702-001-035

red

On/Off

Controlorange

violet

blue

blue

orange

orange

Data from/to

Docker

Power in

from Mains

red

black

brown

brown

red

black

yellow

blue

brown

gray

gray

white

white

3.3 VDC

Motor Pwr

5 VDC

12 VDC

24 VDC

125

18 VDC

Gnd

J10 1314

25.5 VAC2

25.5 VAC1

J10 76

14.4 VAC2

14.4 VAC1

J10 12

120 VAC1

120 VAC2

J10

98

120 VAC2

120 VAC1

J10

2 12

Motor P

wr

Gnd

J9

On/Off

Control

1 11

Motor P

wr

Gnd

J9 19 20

Motor P

wr

Gnd

J13

On/Off

Control

Speed

Control

13 14

Motor P

wr

Reverse

Motor P

wr

Reverse

J13 15 16

Motor P

wr

Forward

Motor P

wr

Forward

Speed

Control

Position

Sensing

13 14

5 VDC

0-5 VDC

Signal

J9 15

Gnd

20 19

Motor P

wr

Reverse

Motor P

wr

Forward

J9

black

red

red

black

23 24

Motor P

wr

Reverse

Motor P

wr

Reverse

J13 21 22

Motor P

wr

Forward

Motor P

wr

Forward

9 10

Motor P

wr

Reverse

Motor P

wr

Reverse

J13 11 12

Motor P

wr

Forward

Motor P

wr

Forward

Speed

Control

Speed

Control

Position

Sensing

Position

Sensing

black

black

gray

12

10

5 VDC

Smoke

Signal

J11

16

11

Gnd

Smoke

Pulse

13Gnd

95 VDC brown

white

blue

black

green

red

15

14

Logic Pwr

5 VDC

J11

52

3.3 VDC

Digital Com

3

Digital Com

1

Reset

8

Gnd

red

orange

white

green

blue

brown

black

129

Vac On/Off

150/60 Hz

Detect

J81011

Gnd

Vac On/Off

2

5

Smoke Sp

Settin

g

6

5 VDC

white

green

black

brown

blue

red

12

3

brown

12

3

Smoke Blower

Motor

Vacuum Pump

Assy

12

12

Cooling Fan

Cooling Fan

gray

gray

Prefill Pump

12

34

12

34

56

Smoke Sensor

(in ULPA Filter)

65

Isolated

Gnd

Digital Com

J12

43

Digital Com

Digital Com

2Digital Com

124 VDC

Level Sensor

12

34

56

7

green

black

blue

white

brown

18

4

Gnd

3.3 VDC(ID)

J9

98

Digital Com

Digital Com

103.3 VDC red

brown

green

white

black

Large Canister

Calibration PCBA

0702-001-803

12

3.3 VDC

Digital Com

J1

34

Digital Com

3.3 VDC(ID)

5

Gnd

16

5

Gnd

Gnd (ID)

J9

76

Digital Com

Digital Com

173.3 VDC red

Small Canister

Calibration PCBA

0702-001-803

12

3.3 VDC

Digital Com

J1

34

Digital Com

Gnd (ID)

5

Gnd

brown

green

white

black

1 2 3 4 5 6 7 8

Large

Regulator

Encoder

Large

Regulator

Motor

1 6

Gnd

Encoder

Pulse

J13 7 17

Encoder

Pulse

3.3 VDC

18

Encoder

Pulse

green

brown

red

blue

1 2 3 4 5 6 7 8

Small

Regulator

Encoder

Small

Regulator

Motor

5 3

Gnd

Encoder

Pulse

J13 4 8

Encoder

Pulse

3.3 VDC

2

Encoder

Pulse

black

orange

yellow

green

brown

red

blue

IV Pole

Brake

IV Pole

Motor

1 2 1 2

Large

Canister

Diverter

Small

Canister

Diverter

1 2 3 4

Drain

Valve

Motor

Position

Sensor

1 2 3 4 5

Volume Display PCBA

0702-001-844

Volume Display

65

Gnd

Reset

J143

Digital C

om

Digital C

om

2

3.3 VDC

1

5 VDC

black

brown

blue

white

green

red

red

orange

green

white

blue

brown

black

Power

Coupler Coil

black

black

DC/DC

ConverterLogic Pwr

Important General Diagram Notes:

- PRODUCT MALFUNCTION IS OFTEN DUE TO DAMAGED ELECTRICAL CONNECTORS. TAKE CARE NOT TO DAMAGE

CONNECTOR PINS WITH METER PROBES!

- CHECKING RESISTANCES AT THE AC POWER AND PD PCBA EDGE CONNECTORS VERIFIES CONTINUITY OF WIRE

HARNESS AND INTERNAL COMPONENT WINDINGS. THIS IS THE PREFERRED LOCATION TO BEGIN

TROUBLESHOOTING.

- Resistance and voltage values given are not specifications, but general expected values. These should be used primarily for

determining continuity or basic circuit function.

- Resistance measurements must be made with rover power off and control circuitry disconnected to avoid damage / false readings.

- All voltage measurements (other than transformer primary and secondary) must be taken with component plugged in to avoid false

readings. Needle type probes will be required to contact conductors inside mated connectors.

- Digital communication connections are indicated with dotted lines. Power, ground, and analog signal connections are indicated

with solid lines.

Specific Diagram Notes:

1. Brush motor resistance as measured with a volt meter can vary dramatically based on brush contact with the motor.

2. Resistance shown is the value if checked at the prefill pump with connector removed. A diode in the wire harness prevents

continuity checks at J10 of Power Distribution PCBA. To check continuity there, set meter to DIODE MODE. Attach positive lead

to pin 8 and negative lead to pin 9 of the wire harness. Diode drop measured should be ~ 0.6 VDC. Switch leads and ensure

meter reads “OL”.

3. Voltage applied to smoke blower motor depends on speed setting. It will be 0 VAC with smoke blower off. The speed setting is

communicated from Power Distribution PCBA to AC Power PCBA.

4. Cannot measure voltage at pump due to connector design.

5. Component is speed controlled, so applied voltage will vary rapidly. Volt meter measurements are not possible.

6. Motor Pwr can be checked via technician menu (TECHNICIAN MENU \ VACUUM \ REGULATOR) . It is shown as "PSVOLT". Its

value depends on the power source and should be ~18 VDC when powered by the Docker and 25 - 40 VDC when powered by

mains.

7. Logic Pwr depends on the power source and should be in the range of 18 – 20 VDC. Motor Pwr and Logic Pwr are the same

voltage when docking.

8. High frequency / high voltage signal cannot be measured with volt meter.

9. Actual voltage measured at component will be 2 - 8 volts lower than Motor Pwr.

10. Vacuum Pump On/Off signals are combined with an AND gate on the AC Power board.

11. The voltage supplied by mains may be either 120 VAC (60 Hz) or 230 VAC (50 Hz). Fuses F1 and F2 on the AC Power PCBA are

used to select which is provided. The autotransformer produces 230 VAC on its primary if 120 VAC is supplied. It produces 120

VAC on its primary if 230 VAC is supplied.

12. This voltage is electrically isolated from other voltages in the system. It must be measured using pin 6 as the ground reference.

13. Transformer voltages shown are for the fully loaded condition. Unloaded voltages will be 5-15 VAC higher.Power in

from Docker

Rover Power Coupler PCBA

0702-001-8061

3

Gnd

18 VDC

J3

12

VAC1

VAC2

J2

1 2

N/C

5 VDC

J1 3 4

3.3 VDC

Digital C

om

from Docker

5

Digital C

om

from Docker

6

Digital C

om

to Docker

7

Digital C

om

to Docker

8

Gnd

AC Power PCBA

0702-001-802

F1(230VAC selector)

F2(120VAC selector)

F4(6.3 A)

F3(10 A)

On/Off

Control

On/Off/

Speed

Control

4 9

Common

120 VAC

J2 20

230 VAC

523

Common

120 VAC

J2

14

22

Common

120 VAC

316

Common

40-65 VAC

J2

13

18

Common

230 VAC

J2

11

Common

Common

J2

11

12

120 or 230

VAC120 or 230

VAC

J2

65

5 VDC

Smoke Sp

Setting

J1

43

Vac On/Off

2

Gnd

2

50/60 Hz

Detect

1

Vac On/Off

1

blue

Position

Sensing

Smoke

Sensing

Calibration

Reading

Radio PCBA

0702-014-028

Note 3

Note 3 Note 10

Note 4

Note 7

Note 6

Note 5Note 5Note 5

Note 9Note 9

Note 5

Note 11

Note 11

IR

IR

S/N PCBA

0702-001-815

12

3.3 VDC

Gnd

J1

34

Digital Com

Digital Com

5Digital Com

6Digital Com

7Gnd

83.3 VDC

Rover Main Controller PCBA

0702-001-800

Main Display

76

Gnd

Reset

J4

54

Digital Com

Digital Com

33.3 VDC

25 VDC

1Logic Pwr

1 2

5 VDC

3.3 VDC

J3 4 3

Digital C

om

Digital C

om

5

Reset

6

Gnd

87

Gnd

Digital C

om

to Docker

J265

Digital C

om

to Docker

Digital C

om

from Docker

4

Digital C

om

from Docker

3

3.3 VDC

2

5 VDC

1

20 VDC

Note 7

Rover

Main

Controller

87

3.3 VDC

Gnd

J11

65

Digital Com

Digital Com

4

Digital Com

3

Digital Com

2

Gnd

1

3.3 VDC

12

3

15

28

46

73

Auto Power Xfmr

0702-001-830

Primary Secondary

120 VAC

14.4 VAC

25.5 VAC

Note 12

Note 8

EMC Filterbrown

blue

green/yellow

Component

Resistance

Chart:

Cooling Fans

Prefill Pump

Small Regulator Motor

Large Regulator Motor

Smoke Blower Motor

Vacuum Pump Motor

Component

Winding

Resistance

(Ohms)

5

1 - 10

285

30

1 - 20

1 - 20

See

Note

1

2

1

1

IV Pole Motor 1 - 20 1

IV Pole Brake 120

Small Canister Diverter 13

Large Canister Diverter 13

Drain Valve 1 - 220 1

Power Coupler Coil 0.5

Note 13

Edge Connectors and pin counting for Power

Distribution and AC Power PCBA’s

J1

1 3

4 6

J2

1 12

13 24

J13

1 12

13 24

J8

1 6

7 12

J9

1 10

11 20

J10

1 7

8 14

J11

1 8

9 16

This drawing shows sheet metal mounted

connectors, viewed from the back of the

rover with circuit boards removed.

1 3

4 6

J12

System Wiring Diagrams-090622-SREA

Docker Main Controller PCBA

0702-014-500

Power

Switch / CB

120 VAC

from Mains

62

N/C

N/C

J437

12.8 VAC 2

12.8 VAC 1

4

23 VAC 2

8

23 VAC 1

1

120 VAC 2

5

120 VAC 1

red

red

blue

blue

green

green

Actuator Stepper

Motor

Couplings

Extended

Hall Sensor

Couplings

Retracted

Hall Sensor

Coupling

Door Hall

Sensor

Data from/to

Rover

Power

Coupler Coil

black

black

Power out to

Rover

16

15

N/C

Gnd

J12

14

13

Gnd

3.3 VDC

125 VDC

1112 VDC

10Motor Pwr

9Motor Pwr

87

Digital Com

Digital Com

65

Digital Com

Digital Com

4

Digital Com

from Rover

3

Digital Com

from Rover

2

Digital Com

to Rover

1

Digital Com

to Rover blue

black

brown

green

white

tan

gray

purple

red

red

red

orange

yellow

black

black

pink

Electro-

magnet

Electro-

magnet

On/Off

Control

21

Gnd

Motor Pwr

J7

21

Gnd

Motor Pwr

J8

black

black

black

black

1 10

5 VDC

Signal

J10 4

Gnd

8 5

5 VDC

Signal

J10 11

Gnd

7 9

5 VDC

Signal

J10 2

GND

1 2 31 2 3 4 1 2 3 1 2 3 4

3 4

Motor P

wr/

Gnd

Motor P

wr/

Gnd

J3 2 1

Motor P

wr/

Gnd

Motor P

wr/

Gnd

green

green/white

red

red/white

Stepper

Motor

Control

Docker Main Controller

F3(6A)

F2(6A)

3 6

120 VAC1

120 VAC2

J91 4

120 VAC1

120 VAC2

J9 2 5

120 VAC1

120 VAC2

J9

purple

orange

1 2 31 2 3

orange

orange

gray

gray

On/Off

Control

On/Off

Control

On/Off

ControlD23 D30Coupling Test

Buttons

1 2 3 4

Soap

Pump

Water

Solenoid

Offload

Pump

87

3.3 VDC

Gnd

J11

65

Digital Com

Digital Com

4

Digital Com

3

Digital Com

2

Gnd

1

3.3 VDC

S/N PCBA

0702-001-815

12

3.3 VDC

Gnd

J1

34

Digital Com

Digital Com

5Digital Com

6Digital Com

7Gnd

83.3 VDC

D29 D17D22

Questra Controller

Docker Power Coupler PCBA

0702-014-510

12

VAC1

VAC2

J1

Power

Coupler

Driver

12

Digital Com

to RoverDigital Com

to Rover

J3

34

Digital Com

from RoverDigital Com

from Rover

5

Digital Com

6

Digital Com

7

Digital Com

8

Digital Com

910

Motor Pwr

Motor Pwr

11

12

12 VDC

5 VDC

13 3.3 VDC

14 Gnd

15 Gnd

16 N/C

IR

IR

3.3 VDC

5 VDC

12 VDC

DC/DC

ConverterLogic Pwr

Motor Pwr

D27

D26

D25

D21 D20 D18

15

26

48

37

12

34

Docker Isolation Xfmr

0702-014-520

Primary Secondary

12.8 VAC

23 VAC

120 VAC

Note 3

Note 4

Note 6

Note 5

Note 7

Note 8

120 VAC

120 VAC

brown

blue

D14

D28

yellow

purple

white

orange

blue

brown

red

green

black

Component

Resistance

Chart:

Soap Pump

Water Solenoid

Offload Pump

Actuator Stepper Motor

Power Coupler Coil

Electromagnets

Component

Winding

Resistance

(Ohms)

375

< 1.0

30

220

N/A

2

See

Note

2

1

9

Docker Main Controller Software

Status LEDs: (See Notes 11, 12)

LED Label

D25

D26

D27

System Condition / Defect

ON

ON

(dim)

ON

ExpectedQuestra Com

Lost

Power Coupler

PCBA Com

Lost

ON

FLASH

(10s / 10s)

OFF

ON

FLASH

(0.25s / 0.25s)

ON

Questra Controller

Software Status LEDs:(See Notes

11, 13)

LED Label

D21

D20

D18

System Condition

ON

ON

OFF

Expected(no ethernet

connection)

Expected(with ethernet

connection)

FLASH

ON

OFF

Important General Diagram Notes:

- PRODUCT MALFUNCTION IS OFTEN DUE TO DAMAGED ELECTRICAL CONNECTORS.

TAKE CARE NOT TO DAMAGE CONNECTOR PINS WITH METER PROBES!

- BOTH THE DOCKER MAIN CONTROLLER AND POWER COUPLER PCBA’S HAVE LARGE

CAPACITORS THAT RETAIN CHARGE FOR EXTENDED PERIODS OF TIME. POWER

MUST BE REMOVED FROM THE DOCKER FOR 3 MINUTES PRIOR TO CONNECTING OR

DISCONNECTING ANYTHING FROM THESE PCBA’S!

- CHECKING RESISTANCES AT THE CONNECTORS TO THE DOCKER CONTROLLER

PCBA VERIFIES CONTINUITY OF WIRE HARNESS AND INTERNAL COMPONENT

WINDINGS. THIS IS THE PREFERRED LOCATION TO BEGIN TROUBLESHOOTING.

- Resistance and voltage values given are not specifications, but general expected values.

These should be used primarily for determining continuity or basic circuit function.

- Resistance measurements must be made with docker power off and control circuitry

disconnected (unplug wire harness from PCBA) to avoid damage / false readings.

- All voltage measurements (other than transformer primary and secondary) must be taken with

component plugged in to avoid false readings. Needle type probes will be required to contact

conductors inside mated connectors.

- Digital communication connections are indicated with dotted lines. Power, ground, and analog

signal connections are indicated with solid lines.

Specific Diagram Notes:

1. The offload pump has an internal rectifier that prevents making resistance measurements. To

check continuity, put meter in DIODE MODE. Measured voltage drop through the pump should

be ~ 1.1 VDC when checked in both directions.

2. Resistance shown is the value if checked at the prefill pump with connector removed. A diode

in the wire harness prevents continuity checks at the Main Controller end of the wire harness.

To check continuity there, set meter to DIODE MODE and remove connector from J9 of the

PCBA. Attach positive lead to purple wire and negative lead to orange wire. Diode drop

measured should be ~0.6 VDC. Switch leads and ensure meter reads “OL”.

3. Cannot measure voltage at pump due to connector design. Voltage can be measured at

Docker Controller PCBA. With pump off, measured voltage will be < 100 VAC. With pump on,

measured voltage will be ~120 VAC.

4. Component is current controlled, so applied voltage will vary rapidly. Volt meter measurements

are not possible.

5. Motor Pwr depends on power source and should be in the range of 25 - 40 VDC.

6. Logic Pwr depends on the power source and should be in the range of 18 – 20 VDC.

7. High frequency / high voltage signal cannot be measured with volt meter.

Docker Main Controller Map:

Docker

Main

Controller

Software

Status

LEDs

Extend/Retract

Test Buttons

Retracted LED

(D23)

Extended LED

(D30)

J9

4 6

1 3

J4

85

41

Soap Pump LED

(D29)

Offload Pump LED

(D22)

Water Solenoid LED

(D17)

Electromagnet LED

(D14)

J12

9 16

1 8

J10

7 12

1 6

J3

4

1

J7

1

2

(D25)

(D26)

(D27)

Coupling Door LED

(D28)

Questra

Controller

Software

Status

LEDs

J8

1

2

(D20)

(D18)

(D21)0702-014-500

Revision Level

12

12

Note 10

Note 10

F4

Note 14

Note 15

Specific Diagram Notes (continued):

8. The voltage supplied by mains may be either 120 VAC (60 Hz) or 230 VAC (50 Hz). Input

voltage is selected by installing the appropriate wire harness P/N between the power switch and

transformer. The main diagram shows the Docker wired for 120 VAC mains.

9. The resistance of both stepper motor phases should be checked. Check resistance from green

wire to green/white. Check resistance from red wire to red/white.

10. Hall signal indicator LED’s are ON when hall sensors are un-plugged.

11. The software status LED states specified in this table apply after the Docker power up

sequence is complete and when no Rover is attached. The Docker power up sequence is

complete 90 seconds after power is applied.

12. Questra Com Lost condition requires replacing Docker Controller PCBA. Power Coupler Com

Lost condition requires troubleshooting of Power Coupler PCBA (check for power and continuity

of communication lines).

13. Conditions other than those shown may require replacing Docker Controller PCBA.

14. Fuse and fuse holder was not included in PCBA revisions prior to H.

15. Transformer voltages shown are for the fully loaded condition. Unloaded voltages will be 5-15

VAC higher.

Wired for 230 VAC mains

Power

Switch / CB

230 VAC

from Mains

12

34

Docker Isolation Xfmr

0702-014-520

Primary Secondary

12.8 VAC

23 VAC

120 VAC

120 VAC

120 VACbrown

blue

Hardware LED Indicators: (See Note 10)

Couplings Retracted

Soap Pump State

Offload Pump State

Water Solenoid State

Couplings Extended

Coupling Door

LED

Label

D28

D30

D23

D29

D22

D17 ON = ON

LED

Electromagnet State D14

Docker Main

Controller PCBA

Revision Level

ON = OFF ON = ON

ON = ON

ON = ON

A - F HLED Label

Triggered

Condition

Door Closed

Extended

Retracted

LED State

if Triggered

OFF

ON

ON

Signal if

Triggered

0 VDC

3.3 VDC

3.3 VDC

LED

System Wiring Diagrams-090622-SREA

Rover

RF Module

0702-014-028

Wireless

Controller

Docker

Docker Power Coupler PCBA

0702-014-510Docker Main Controller PCBA

0702-014-500

Rover Main Controller PCBA

0702-001-800

Power Distribution PCBA

0702-001-035

Volume Display PCBA

0702-001-844

Rover Main

Controller

EDMS

Ministamp

EDMS Main

Stamp

Docker Main

Controller

Docker

Power

Coupler

Controller

Smoke

Controller

Tank (Valve)

Controller

Level

Sensor

FPGA

Large

Vacuum

Regulator

Controller

Small

Vacuum

Regulator

Controller

IV Pole

Controller

Canister

Reader

Controller

Volume

Display

Controller

Rover Power Coupler PCBA

0702-001-806

IR

IRIR

IR

Data

Transfer

Power

Transfer

System Control Overview

Electrical

System Control Overview-090623-SREA

2 - Fluid_Waste_Subsystem-Thoery of Oper3 - Fresh_Water_Subsystem-Theory of Oper4 - Level_Sensor_Subsystem-Theory of Oper5 - Smoke_Evacuator_Subsystem-Theory of Oper6 - Vacuum_Subsystem-Theory of Oper7 - Coupling_Actuation_Subsystem-Theory of Oper8 - IV_Pole_Subsystem-Theory of Oper1 - System_Wiring_Diagrams-090622-SREA1a - System_Control_Overview-090623-SREA